External panel of the B-pillar (Freelander 2)

CAUTION: The outer B-pillar panel should be MIG spot-welded to the B-pillar reinforcement (which is made of BH300 heat-treated steel) and the inner bottom rail panel reinforcement (which is made of DP600 (dual phase steel)). Plug-in rivets/MIG spot welds should not be used.

NOTE: The outer "B" pillar panel is serviced as a separate weld-on panel.

NOTE: There is an NVH element mounted inside this panel; it is not serviceable on a new panel. If damaged, a new element will be required.

NOTE: If the B-pillar outer panel is being replaced without the B-pillar reinforcement, the top section butt joint can be made lower on the pillar if desired.

Removal

1. When replacing the outer panel of the B-pillar, the following elements are removed:

• Front door
• Back door
• Ceiling lining

2. For additional information on this repair procedure, refer to the following sources: For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation) / Standard Service Station Techniques (100-00 General Information, Description and Operation).

3. Remove the front door. For more information, refer to the chapter: Front Door (501-03 Lockable Body Parts, Removal and Installation).

4. Remove the rear door. For more information, refer to the chapter: Rear Door (501-03 Lockable Body Parts, Removal and Installation).

5. Remove the upper and lower door hinges from the B-pillar (four bolts).

6. Remove the front door lock mating part from the B-pillar.



7. Remove the front seat. For more information, refer to the chapter: Front Seat (501-10 Seat, Removal and Installation).

8. Remove the rear seat cushion. For more information, refer to the chapter: Rear Seat Cushion (501-10 Seat, Removal and Installation).

9. Remove the front seat belt retractor. For more information, refer to the chapter: Front Seat Belt Retractor (501-20A Seat Belt System, Removal and Installation).

10. Remove the headlining. For more information, refer to the chapter: Upper Trim - Vehicles not equipped with: Tilting Sunroof (501-05 Interior Trim, Removal and Installation) / Upper Trim - Vehicles equipped with: Tilting Sunroof (501-05 Interior Trim, Removal and Installation).

11. Remove the left and right lower trim inner panels.

12. Remove the side impact sensor from the B-pillar. For more information, refer to the chapter: Side Impact Sensor of the B-Pillar (501-20B Supplemental Restraint System, Removal and Installation).

13. Remove the side airbag module. For additional information, refer to: Side Airbag Module (501-20B Supplemental Restraint System, Removal and Installation).

14. Remove the front and rear roof molding sections.

15. Remove the lower trim panel outer molding.

16. Release and set aside the front section of carpet.

17. Remove the rear section of carpet.

18. Release and set aside the wiring harness that runs along the inside of the B-pillar and the inside of the lower trim panel.

19. Cut the old panel as shown, following the dimensions given, to allow access to the 'B' post reinforcement.





20. Cut the old panel where it meets the bottom trim panel, allowing for an overlap onto the new panel; use the new panel as a template.

21. Mill out the contact welding areas.



22. Separate the connections and remove the old panel, also releasing the NVH element.

Installation

1. Position the new panel and secure it in the required position, ensuring that it overlaps the old panel remaining on the vehicle.



2. Cut new and old panels to the bottom trim panel where MIG butt joints are to be made.



3. Cut new and old panels at the top joint where the MIG butt joint is to be made.



4. Remove the new panel and the remains of the old panel.

5. Cut holes in the new panel prepared for MIG soldering.

NOTE: MIG welding holes should be positioned in accordance with the intervals shown in the illustration. Where this is not possible due to dents in the panel, the hole should be made at the location of the original spot weld.

6. Prepare the mating surfaces of the old and new panels.



7. Replace the NVH element if necessary.

8. Apply adhesive to the NVH element.



9. Position the new panel in the desired location and secure it in place. Check the alignment. If it is correct, proceed to the next step. If not, make the necessary adjustments and recheck before continuing.

10. Make tack welds for butt joints.

11. Perform through-hole MIG soldering.



12. Clean the tack welds.

13. Perform butt welding joints using MIG technology.



14. Clean all welds.

15. Installation of appropriate panels and mechanical elements is performed in the reverse order of removal.